Turbocharger with rotating electric machine

ABSTRACT

A turbocharger with a rotating electric machine includes a turbine rotor which constitutes a portion of a rotating member of the turbocharger; a compressor impeller which constitutes a portion of the rotating member of the turbocharger; a rotating electric machine which includes a stator and a rotor that constitutes a portion of the rotating member of the turbocharger; a shaft which supports the turbine rotor at one end and the compressor impeller at the other end, and which supports the rotor of the rotating electric machine at an intermediate portion; bearings each of which has an inner race and an outer race, and one of which supports the shaft at a portion between the one end and the intermediate portion, and the other of which supports the shaft at a portion between the other end and the intermediate portion; and a cylindrical member which encases the rotor of the rotating electric machine at a center portion and which contacts the inner race of one of the two bearings at one end portion and the inner race of the other of the two bearings at the other end portion.

This is a Continuation of application Ser. No. 10/958,399 filed Oct. 6,2004, now U.S Pat. No 6,943,468. The entire disclosure of the priorapplication is hereby incorporated by reference herein in its entirety.

INCORPORATION BY REFERENCE

The disclosure of Japanese Patent Application No. 2003-357273 filed onOct. 17, 2003 including the specification, drawings and abstract isincorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a turbocharger for an internal combustionengine. More particularly, the invention relates to a turbocharger witha rotating electric machine, which includes a rotating electric machinesuch as an electric motor or an electric motor-generator.

2. Description of the Related Art

A turbocharger with a rotating electric machine is generally configuredto include a rotating member of the turbocharger in which a shaft, thatsupports a turbine rotor at one end and a compressor impeller at theother end and that supports a rotor of the rotating electric machine atan intermediate portion, is supported by bearings, each of which has aninner race and an outer race, at a portion between the one end and theintermediate portion and a portion between the other end and theintermediate portion. Japanese Patent Laid-Open Publication No.2000-145469 discloses a technology in which a rotor of a rotatingelectric machine is reinforced by being covered with a reinforcingsleeve in order to prevent damage to a magnet constituting the rotor ofthe rotating electric machine caused by a strong centrifugal force dueto high speed rotation of a rotating member of a turbocharger, in aturbocharger with a rotating electric machine having the above-mentionedconfiguration. Also, this publication discloses a technology in which atube-like spacer is provided in each of a portion between one end of therotor of the rotating electric machine and a bearing adjacent theretoand a portion between the other end of the rotor of the rotatingelectric machine and a bearing adjacent thereto, in order to maintain anaxial position of the rotor of the rotating electric machine in therotating member of the turbocharger.

Meanwhile, heat due to eddy currents is generated in a rotor of arotating electric machine. Accordingly, Japanese Patent Laid-OpenPublication 2001-25209 discloses a technology in which a spiral holepenetrating the rotor in the axial direction is formed in the rotor andair or a cooling medium flows through the spiral hole.

In order to stably operate a turbocharger with a rotating electricmachine, it is requested that heat generated in the rotating electricmachine be appropriately released. It is also requested that a magnet ofa rotor of the rotating electric machine containing relatively brittlematerial be protected from damage due to a centrifugal force, an axialposition of the rotor of the rotating electric machine be stablymaintained in the rotating member of the turbocharger, and the like.Namely, these requests to the turbocharger with a rotating electricmachine need to be satisfied with a simple configuration.

SUMMARY OF THE INVENTION

The invention is made in the light of the above-mentioned circumstances.According to an aspect of the invention, there is provided aturbocharger with a rotating electric machine, including a cylindricalmember extending between bearings, to be described. The turbochargerwith a rotating electric machine includes a turbine rotor whichconstitutes a portion of a rotating member of the turbocharger; acompressor impeller which constitutes a portion of the rotating memberof the turbocharger; a rotating electric machine which includes a statorand a rotor that constitutes a portion of the rotating member of theturbocharger; a shaft which supports the turbine rotor at one end andthe compressor impeller at the other end, and which supports the rotorof the rotating electric machine at an intermediate portion; bearingseach of which has an inner race and an outer race, and one of whichsupports the shaft at a portion between the one end and the intermediateportion, and the other of which supports the shaft at a portion betweenthe other end and the intermediate portion; and a cylindrical memberwhich encases the rotor of the rotating electric machine at a centerportion and which contacts the inner race of one of the two bearings atone end portion and the inner race of the other of the two bearings atthe other end portion.

In the turbocharger with a rotating electric machine having theabove-mentioned configuration, that includes the rotating member inwhich the shaft, that supports the turbine rotor at one end and thecompressor impeller at the other end and that supports the rotor of therotating electric machine at the intermediate portion, is supported bythe bearings, each of which has the inner race and the outer race, atthe portion between one end and the intermediate portion and at theportion between the other end and the intermediate portion, when theturbocharger is configured to have the cylindrical member which encasesthe rotor of the rotating electric machine at the center portion andwhich contacts the inner race of one of the two bearings at one endportion and the inner race of the other of the two bearings at the otherend portion, the cylindrical member produces an effect of protecting themagnet of the rotor of the rotating electric machine from damage due toa centrifugal force and an effect of recovering heat generated in therotating electric machine by fully encasing the rotor of the rotatingelectric machine at the center portion. Also, by contacting the innerrace of one of the two bearings at one end portion and the inner race ofthe other of the two bearings at the other end portion while fullyenclosing the rotor of the rotating electric machine at the centerportion, it is possible to simultaneously achieve an effect of stablymaintaining the axial position of the rotor of the rotating electricmachine in the rotating member of the turbocharger and an effect oftransferring heat collected by the rotor of the rotating electricmachine at the center portion and releasing the heat to a cooling systemusing lubricating oil. The cylindrical member includes the centerportion which fully encases the rotor of the rotating electric machine,integral with the portion extending from the center portion to one ofthe bearings and the portion extending from the center portion to theother bearing. Therefore, when the center portion is subjected to aforce applied in a radial pattern due to a centrifugal force of therotor of the rotating electric machine, strength and durability of thecenter portion of the cylindrical member, which suppresses the forceapplied in the radial pattern, largely increases compared with the casewhere the sleeve which covers only the rotor portion of the rotatingelectric machine is used.

BRIEF DESCRIPTION OF THE DRAWINGS

The above mentioned embodiment and other embodiments, objects, features,advantages, technical and industrial significance of this invention willbe better understood by reading the following detailed description ofthe exemplary embodiments of the invention, when considered inconnection with the accompanying drawings, in which:

FIG. 1 is a longitudinal section view schematically showing aturbocharger according to a first embodiment of the invention, whichincludes a cylindrical member extending between bearings;

FIG. 2 is a longitudinal section view schematically showing only arotating electric machine of a turbocharger according to a secondembodiment of the invention. An outer peripheral end portion of each ofdiameter reducing portions of a rotating electric machine in FIG. 1 isformed to be an edge portion; and

FIG. 3 is a longitudinal section view showing only a stator in arotating electric machine of a turbocharger according to a thirdembodiment of the invention. A spiral groove is formed in an innersurface of the stator of the rotating electric machine in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the following description and the accompanying drawings, the presentinvention will be described in more detail in terms of exemplaryembodiments.

FIG. 1 is a longitudinal section view schematically showing aturbocharger with a rotating electric machine according to a firstembodiment of the invention, which includes a cylindrical memberextending between bearings. In FIG. 1, a reference numeral “10”signifies a turbine, a reference numeral “12” signifies a compressor,and a reference numeral “14” signifies a rotating electric machine. Ashaft 22 which supports a turbine rotor 16, a compressor impeller 18,and a rotating electric machine rotor 20 is rotatably supported by abearing 26 at a shaft portion 24 between the turbine rotor 16 and therotating electric machine rotor 20. Also, the shaft 22 is rotatablysupported by a bearing 30 at a shaft portion 28 between the compressorimpeller 18 and the rotating electric machine rotor 20. The rotatingelectric machine 14 includes a stator 32 which is provided around therotating electric machine rotor 20. The stator 32 includes a core 34 anda coil 36 (only two representative ones are shown in FIG. 1).

The bearing 26 is lubricated and cooled by lubricating oil which issupplied from an oil passage 38 and released through an oil passage 40.The bearing 30 is lubricated and cooled by lubricating oil which issupplied from an oil passage 42 and released through an oil passage 44.

A reference numeral “46” signifies a cylindrical member providedaccording to the invention. The cylindrical member 46 encases therotating electric machine rotor 20 at a center portion 46 a, andcontacts an inner race of the bearing 26 at an end portion 46 b and aninner race of the bearing 30 at an end portion 46 c. In the cylindricalmember 46, a diameter reducing portion 46 d, whose diameters isgradually reduced, is formed in a portion extending from the centerportion 46 a, which encases the rotating electric machine 20, to an endportions 46 b. Also, a diameter reducing portion 46 e, whose diameter isgradually reduced, is formed in a portion extending from the centerportion 46 a to an end portion 46 c. In the embodiment shown in FIG. 1,the diameter of each of the diameter reducing portions 46 d and 46 e isgradually reduced such that the outline of the diameter reducing portionseen in the longitudinal section view has an angle of substantially 45degrees, and each of the diameter reducing portions 46 d and 46 e isformed as a choanoid inclined surface. The diameter of the diameterreducing portion may be reduced at another angle. Alternatively, thediameter of the diameter reducing portion may be reduced in stages. Sucha diameter reducing portion is configured to extend in a radial pattern.Therefore, the strength against a centrifugal force applied to therotating member of the turbocharger during rotation thereof isincreased. In addition, support of the center portion 46 a in thecentripetal direction, strength of the center portion 46 a for encasingthe rotating electric machine 20, and durability of the center portion46 a are all increased.

Due to provision of the cylindrical member 46, the cylindrical member 46contacts the inner race of the bearings 26 at the end portions 46 b andthe inner race of the bearing 30 at the end portion 46 c, while fullyencasing the rotating electric machine rotor 20 at the center portion 46a. The cylindrical member 46 produces an effect of stably maintainingthe axial position of the rotating electric machine rotor 20, and aneffect of transferring the heat, which is recovered from the electricrotating machine rotor 20 at the center portion 46 a, to the bearings 26and 30, and releasing the heat to a lubricating cooling system using thelubricating oil. The lubricating oil is supplied from the oil passages38 and 42, crosses the bearings 26 and 30, and released through the oilpassages 40 and 44.

When part of the lubricating oil supplied from the oil passages 38 and42 to the bearings 26 and 30 leaks through ring-shaped clearances 48 and50, and adheres to the outer surfaces of the diameter reducing portions46 d and 46 e, respectively, the lubricating oil is shaken off to theperipheral area due to a centrifugal force generated by rotation of therotating member of the turbocharger. Accordingly, part of the heat,which is recovered by the cylindrical member 46 at the center portion 46a using the rotating electric machine rotor 20, is contained in an oildrop, and is released from the rotating electric machine rotor 20. Inaddition, in the embodiment in FIG. 1, the oil drop which is shaken off,is supplied particularly to the portion of the coil 36, and provides abetter cooling effect to the stator 32 at the portion of the coil 36having a high degree of roughness.

Hereafter, a turbocharger with a rotating electric machine according toa second embodiment will be described with reference to FIG. 2. FIG. 2is a view showing a case where an edge portion, with which an oil dropcan be released easily, is formed at each of outer peripheral endportions of the diameter reducing portions 46 d and 46 e, in order toenhance an effect of shaking off the oil, which adheres to the outersurfaces of the diameter reducing portions 46 d and 46 e of thecylindrical member, due to rotation of the rotating member of theturbocharger. FIG. 2 is a cross sectional view showing only the rotatingmember of the turbocharger shown in FIG. 1. In FIG. 2, the rotatingelectric machine portion is enlarged to a certain extent compared withthat in FIG. 1. In FIG. 2, the same reference numerals are assigned tothe same portions as those in FIG. 1. By forming the edge portion 46 fat the outer peripheral end portion of the diameter reducing portion 46d, and the edge portion 46 g at the outer peripheral end portion of thediameter reducing portion 46 e, the oil adhering on the diameterreducing portions 46 d and 46 e is urged due to rotation of the rotatingmember of the turbocharger, drained from the outer peripheral endportions of the diameter reducing portions 46 d and 46 e with gooddrainage performance in the centrifugal direction, and shaken off towardthe stator (toward the coil portion in the embodiment in FIG. 2).

Next, a turbocharger with a rotating electric machine according to athird embodiment will be described with reference to FIG. 3. FIG. 3 is aview showing a case where a spiral groove is formed in an inner surfaceof the stator (more particularly, the core portion thereof) of therotating electric machine. FIG. 3 is a cross sectional view showing onlythe stator of the rotating electric machine of the turbocharger shown inFIG. 1. In FIG. 3, the stator is enlarged to a certain extent comparedwith that in FIG. 1. In FIG. 3, the same reference numerals are assignedto the same portions as those in FIG. 1. When a spiral groove 52 isformed in the inner surface of the stator of the rotating electricmachine, the air, which rotates in accordance with rotation of therotating electric machine rotor 20, is guided by a side wall surface ofthe spiral groove 52, and moves in an axial direction of the rotatingelectric machine rotor 20. Therefore, an airflow is generated in aring-shaped clearance between the rotating electric machine rotor andthe stator, and the cooling effect provided to the rotating electricmachine rotor and the stator is increased.

While the invention has been described with reference to exemplaryembodiments thereof, it is to be understood that the invention is notlimited to the exemplary embodiments or constructions. To the contrary,the invention is intended to cover various modifications and equivalentarrangements. In addition, while the various elements of the exemplaryembodiments are shown in various combinations and configurations, whichare exemplary, other combinations and configurations, including more,less or only a single element, are also within the spirit and scope ofthe invention.

1. A turbocharger with a rotating electric machine, comprising a turbinerotor which constitutes a portion of a rotating member of theturbocharger; a compressor impeller which constitutes a portion of therotating member of the turbocharger; a rotating electric machine whichincludes a stator having a coil and a core, and a rotor that constitutesa portion of the rotating member of the turbocharger; a shaft whichsupports the turbine rotor at one end and the compressor impeller at theother end, and which supports the rotor of the rotating electric machineat an intermediate portion; bearings each of which has an inner race andan outer race, and one of which supports the shaft at a portion betweenthe one end and the intermediate portion, and the other of whichsupports the shaft at a portion between the other end and theintermediate portion; and a cylindrical member which encases the rotorof the rotating electric machine at a center portion and which contactsthe inner race of one of the two bearings at one end portion and theinner race of the other of the two bearings at the other end portion,wherein: the cylindrical member has a diameter reducing portion at atleast one of a portion extending from the center portion, which encasesthe rotor of the rotating electric machine, to one end portion and aportion extending from the center portion to the other end portion, thediameter reducing portion is formed such that a diameter of the diameterreducing portion is reduced from the center portion to the end portionin an axial direction of the shaft, and the diameter reducing portion isprovided at a position at which an oil drop, that is produced when oiladhering to an outer surface of the diameter reducing portion is shakenoff by a centrifugal force due to rotation of the rotating member of theturbocharger, contacts the coil of the stator of the rotating electricmachine.
 2. The turbocharger with a rotating electric machine accordingto claim 1, wherein the coil of the stator is arranged to protrudebeyond an edge of the core in a rotational axis direction of therotating electric machine, and the rotating electric machine has aclearance between the core and the rotor.
 3. The turbocharger with arotating electric machine according to claim 1, wherein a portion of thediameter reducing portion has a shape that increases releaseability ofthe oil drop from an outer peripheral surface of the diameter reducingportion.
 4. The turbocharger with a rotating electric machine accordingto claim 3, wherein the portion of the diameter reducing portion isformed to be an edge.